Pultrusion systems that apply lengthwise curvature to composite parts

ABSTRACT

Systems and methods are provided for applying lengthwise curvature to composite parts. One embodiment is a method that includes fabricating a preform for a curved pultruded gap filler by continuously: heating fiber reinforced material to a sticking point temperature for a constituent material within the fiber reinforced material, and feeding the fiber reinforced material through a die that exhibits a curvature through which the fiber reinforced material travels while the fiber reinforced material is heated to the sticking point temperature, the die forming the fiber reinforced material into a preform for a gap filler. Fabricating the curved pultruded preform further includes varying path lengths of fibers within the preform as the preform passes through the die, and pulling the preform out of the die.

FIELD

The disclosure relates to the field of composite materials, and inparticular, to preforms that enhance the strength of joints in compositematerials.

BACKGROUND

Multi-layer laminates of constituent material (e.g., Carbon FiberReinforced Polymer (CFRP)) may be formed into any of a variety of shapesbefore they are cured into an integral composite part. For example, diesand/or other forming tools may be utilized to alter the shape of a sheetof laminate. Some types of laminate have been impregnated with a curableresin, and are referred to as “prepreg” laminate. Other types oflaminate include “dry fiber” which has not been impregnated with resin,and thermoplastic carbon fiber that includes a thermoplastic resininstead of a thermoset resin.

Popular composite parts include the stringers of an aircraft. However,such composite parts may exhibit sharp bends/corners having tight radiidue to the bending of flat layers in order to form a three dimensionalstructure for the stringer. For example, a “hat” stringer used for anaircraft may have joints between laminates, and these joints may exhibittight inner corner radii. A tight inner corner radius on a joint maycause that joint to exhibit less-than desired bond strength when thelaminates are co-cured. A gap filler (colloquially referred to as a“noodle”) is therefore desirable to occupy gaps left over when flatlaminates are folded and matched to other folded or flat laminates. Gapfillers may be fabricated and inserted at the joints to fill gaps leftby folds for those joints. Gap fillers remain desirable for stringersthat exhibit a variety of complex shapes. This may be particularly thecase for laminates that have been laid-up flat and then bent intonumerous shapes to form structures with cross section in the shape ofC's, I's, J's, Z's, etc. For example, a structure forming an “I” shapemade from two back-to-back “C” channels and flat laminates capping offthe “C” channels may include multiple locations for which gap fillersare desired.

Thus, those who design composite parts continue to desire enhancedsystems that are capable of generating gap fillers in a cost-effectivemanner, capable of fabricating gap fillers having desired strength, andare also capable of reducing the incidence and severity of gap fillersthat are out-of-tolerance.

SUMMARY

Embodiments described herein provide for enhanced techniques and systemsthat are capable of automatically pultruding curved gap fillers thatexhibit a radius of curvature along their length that corresponds with acurved stringer. Specifically, embodiments described herein may utilizecurved pultrusion dies with integrated cooling systems to permanentlyenforce a desired geometry onto a material. This automated processincreases the precision and speed at which a curved gap filler may beproduced.

One embodiment is a method that includes fabricating a preform for acurved pultruded gap filler by continuously: heating fiber reinforcedmaterial to a sticking point temperature for a constituent materialwithin the fiber reinforced material, and feeding the fiber reinforcedmaterial through a die that exhibits a curvature through which the fiberreinforced material travels while the fiber reinforced material isheated to the sticking point temperature, the die forming the fiberreinforced material into a preform for a gap filler. Fabricating thecurved pultruded preform further includes varying path lengths of fiberswithin the preform as the preform passes through the die, and pullingthe preform out of the die.

A further embodiment is an apparatus that includes a pultrusion die. Thepultrusion die includes a curved channel that extends internally withinthe die from an entrance of the die to an exit of the die, a coolingchamber internal to the die that is located downstream of the entrance,and multiple passages that are located relative to the cooling chamberthat facilitate heat transfer for the chamber at locations between theentrance and the exit.

A still further embodiment is an apparatus that includes a noodlesupplier that provides fiber reinforced material for forming into apreform for a noodle, a heater that increases a temperature of fiberreinforced material received from the noodle supplier, a die imparting acurvature to material that has been heated, forming the preform, and anoodle tensioning device that tensions the preform, thereby pulling thepreform through the die.

Yet another embodiment is a system that includes at least one spool forholding a roll of fiber reinforced material comprising a constituentmaterial, and a heater downstream of the spool that heats the fiberreinforced material to a sticking point temperature of the constituentmaterial. The system also includes a pultrusion die, downstream of theheater, that exhibits a channel having a lengthwise curvature that isenforced upon a length of the fiber reinforced material, and forms thefiber reinforced material into a preform for a gap filler, a coolingchamber that cools the preform, and rollers that are located downstreamof the pultrusion die and form a nip in a cross-sectional shape of thepultrusion die.

Other exemplary embodiments (e.g., methods and computer-readable mediarelating to the foregoing embodiments) may be described below. Thefeatures, functions, and advantages that have been discussed can beachieved independently in various embodiments or may be combined in yetother embodiments further details of which can be seen with reference tothe following description and drawings.

DESCRIPTION OF THE DRAWINGS

Some embodiments of the present disclosure are now described, by way ofexample only, and with reference to the accompanying drawings. The samereference number represents the same element or the same type of elementon all drawings.

FIG. 1 illustrates a hat stringer in an exemplary embodiment.

FIGS. 2A-2B illustrate further views of a hat stringer in an exemplaryembodiment.

FIGS. 3-4 illustrate a preform for a curved gap filler in an exemplaryembodiment.

FIGS. 5A-5B are diagrams illustrating a pultrusion system forfabricating preforms for curved gap fillers in an exemplary embodiment.

FIGS. 6-8 illustrate various arrangements of rollers for a pultrusionsystem in an exemplary embodiment.

FIGS. 9-11 illustrate further arrangements of rollers for a pultrusionsystem in an exemplary embodiment.

FIG. 12 is a flowchart illustrating a method for operating a pultrusionsystem in an exemplary embodiment.

FIG. 13 is a block diagram of a pultrusion system in an exemplaryembodiment.

FIG. 14 is a flow diagram of aircraft production and service methodologyin an exemplary embodiment.

FIG. 15 is a block diagram of an aircraft in an exemplary embodiment.

DESCRIPTION

The figures and the following description illustrate specific exemplaryembodiments of the disclosure. It will thus be appreciated that thoseskilled in the art will be able to devise various arrangements that,although not explicitly described or shown herein, embody the principlesof the disclosure and are included within the scope of the disclosure.Furthermore, any examples described herein are intended to aid inunderstanding the principles of the disclosure, and are to be construedas being without limitation to such specifically recited examples andconditions. As a result, the disclosure is not limited to the specificembodiments or examples described below, but by the claims and theirequivalents.

FIG. 1 is a perspective view of a curved composite part 100 in anexemplary embodiment. In this embodiment, composite part 100 comprises a“hat” stringer for an aircraft having a multi-layer laminate base 110,and a multi-layer laminate “hat” 120. In this embodiment, each laminatecomprises multiple layers of constituent material, such as carbon fiberin “dry fiber” form (i.e., lacking impregnated resin) that may bestabilized by a binding agent (e.g., a tackifier). After being laid-upand conformed to a desired shape (e.g., via consolidation of apre-form), base 110 and hat 120 are co-cured (e.g., via the applicationof heat in a vacuum) in order to form an integral composite part (e.g.,a cured carbon fiber stringer exhibiting desired strength).

Delving deeper into the geometry of composite part 100, FIGS. 2A-2Bprovide end views of composite part 100 corresponding with view arrows 2of FIG. 1. FIG. 2A is an exploded end view, while FIG. 2B is a standardend view. As shown in FIG. 2B, hat 120 and base 110 unite at joint 220.Without a preform 250 for a gap filler, joint 220 would exhibit a tightradius of curvature. Hence, preform 250 is desired to form joint 220without voids. Hence, part 100 includes preform 250 placed within volume210 at joint 220. Preform 250 may also be referred to as a preform for a“noodle” or “spacer.” Preform 250 fills voids out at joint 220, therebyincreasing the strength of joint 220 and preventing dis-bond betweenbase 110 and hat 120. A laminate wrap 230 is also illustrated to furthersecure preform 250 within composite part 100. The various componentsshown for composite part 100 may be co-cured together in order to unifythem into a single, integral composite part 100.

FIG. 3 is a zoomed in front view of a preform 250 for a gap filler.Specifically, FIG. 3 corresponds with view arrows 3 of FIG. 2B. As shownin FIG. 3, preform 250 exhibits a width W and a thickness T. Theseproperties may vary along the length of preform 250, and the width mayeven vary within preform 250. In this embodiment, preform 250 includesfibers 330 (e.g., carbon fibers) integrated with (or within) a binder340. Binder 340 may comprise a thermoplastic veil, thermoset resin, oreven a combination thereof. Meanwhile, the carbon fibers may becontinuous and straight, or may even be woven, braided, or comprisechopped fiber in random orientations. Note that in some embodiments,preform 250 may be made from one or more layers/plies of material.Individual layers/plies are not illustrated in FIG. 4 for referencepurposes, as a single ply embodiment is shown.

FIG. 4 is a top view of preform 250 of FIG. 3. FIG. 4 illustrates thatpreform 250 is curved along its length (L). FIG. 4 further illustratesthat fibers 330 within preform 250 are oriented such that they extendalong the length of preform 250 as preform 250 curves. While preform 250is shown as being roughly ten times as long as its width in FIG. 4, itshould be understood that preform 250 may be particularly long (e.g., onthe order of tens of meters) and particularly narrow (e.g., varying inwidth but averaging a few centimeters), and may result from a continuousmanufacturing process. In embodiments wherein long continuous fibers areutilized to form preform 250, preforms 250 may be spliced together inorder to increase length.

With the properties of preform 250 readily described above, FIGS. 5-11illustrate systems that automatically fabricate curved preforms. FIG. 5Ais a diagram illustrating a pultrusion system 500 for fabricatingpreforms for curved gap fillers in an exemplary embodiment. Pultrusionsystem 500 is capable of pultruding a tape 520 of material in order topermanently enforce a desired curvature onto the tape 520. Tape 520 isheated above a sticking point temperature during pultrusion and thencooled after the curvature has been enforced in order to permanentlychange shape into a preform. That is, the transition temperatureactivates the binding properties of a constituent material (e.g., atackifier) of tape 520. The preform may then be placed within a laminatewithout wrinkling or bunching within the laminate. Thus, the strength ofa resulting composite part cured from the laminate will be enhanced.

Pultrusion system 500 operates to unwind a roll of tape 520 (comprising,e.g., a carbon fiber reinforced material) from spool 510 (at locationL1), heat tape 520 above a sticking point temperature for a material(e.g., a thermoplastic binder or thermoset binder) within tape 520 (atlocation L2), and feed tape 520 through a die 550 (at location L3)having a channel that enforces a curvature onto tape 520. Pultrusionsystem 500 further cools tape 520 as tape 520 travels through die 550(at location L4), and pulls tape 520 out of die 550 (at location L5).This results in a curved, pultruded preform 250 exiting pultrusionsystem 500.

In this embodiment, pultrusion system 500 includes spool 510, whichstores wound tape 520 for shaping into a preform 250 for a curved gapfiller. Spool 510 may also be referred to as a “noodle supplier,” as itsupplies material for forming into a “noodle.” Tape 520 may comprise anysuitable material capable of undergoing plastic deformation prior tocuring into a composite part. In this embodiment, a length of tape 520comprises carbon fibers (e.g., 512, 514) which extend lengthwise withintape, in addition to a thermoplastic binder (e.g., binder 340 of FIG.3), a thermoplastic veil, etc.

Tape 520 is unwound from spool 510 proceeds past heaters 530, whichapply heat (A) to tape 520 that causes the thermoplastic veil (or athermoset resin) to reach or exceed a sticking point temperature and/orglass transition temperature (e.g., 80-160° Celsius (C) for thermosetresins, or 140-240° C. for thermoplastic veils). The heating ensuresthat tape 520 is capable of being reshaped by die 550 without fracturingor breaking. Heaters 530 may comprise any suitable heating components,such as radiant heaters that utilize an infrared radiant heatingelement. In further embodiments, multiple plies (e.g., multiple reels oftape from multiple spools 510) are unwound, tacked together, and heatedin order to prepare the batch of plies for pultrusion into a singlepreform 250.

After tape 520 passes heaters 530, tape 520 is fed into entrance 552 ofdie 550, which includes a curve 554 that facilitates entry of tape 520into die 550. Die 550 includes a curved channel 556 through which tape520 is drawn. Channel 556 exhibits a curvature which is applied to tape520 by the time that tape 520 exits die 550. In this embodiment, die 550is formed from piece 560, which defines an inner radius 562, and piece570, which defines an outer radius 572. Piece 560 forms a lower half ofchannel 556, and piece 570 forms an upper half of channel 556. Entrance552 of die 550 may exhibit a circular inlet geometry in someembodiments. In such embodiments, channel 556 may transition along itslength, sweeping from a large net cross-section to a smaller netcross-section, or channel 556 may be formed by sweeping a net crosssection along a desired radius.

As tape 520 is fed through die 550, tape 520 is forced into across-sectional shape (557, shown in FIG. 5B) defined by die 550 (e.g.,at hundreds of pounds of pressure). Tape 520 is further actively curvedinto a desired shape by channel 556. Because a curvature will beenforced upon tape 520, fibers 512 and 514 within tape 520 will slipwith respect to each other within die 550. That is, fiber 512 at anouter radius 572 will utilize more fiber length than fiber 514 which isat an inner radius 562. This slippage occurs between fibers of tape 520.In embodiments wherein multiple plies of tape 520 are pultruded togetherto form a single preform 250, individual layers of tape may sliprelative to each other when pultruded, causing fibers in outer plies toform a radius of greater length than the inner radius, similar to theouter lanes of a running track when compared to the inner lanes. Theslippage may exist even when the average radius of curvature is large(e.g., fifty to one hundred inches) and the difference between inner andouter radius is small (e.g., one quarter of an inch). Thus, by feedingtape 520 through channel 556 of die 550, pultrusion system 500 enforcesvarying path lengths between fibers within tape 520. By enforcingslippage between fibers relative to each other while the fibers arebeing actively shaped by pultrusion through die 550, pultrusion system500 prevents the formation of wrinkles in the resulting preform 250. Die550 may be constructed, for example, from metal or from a resilientplastic.

Each piece of die 550 also includes a cooling chamber 564 through whichpressurized fluid 566 (e.g., gaseous compressed air, liquid water, or arefrigerant) may travel. The pressurized fluid 566 is cooled below thedesired temperature (e.g., to ambient temperature or below), and thepressurized fluid 566 is blown through passages 568 onto tape 520 astape 520 travels within die 550. In some embodiments, liquids andchemical refrigerants are used to cool tape 520 by conduction through anevaporator or conventional refrigeration circuit. In such embodiments,die 550 may be dimensioned such that these liquids do not directlycontact tape 520 during cooling.

In this manner, tape 520 (and/or die 550) is rapidly cooled below thesticking point temperature via forced convective heat transfer with thepressurized fluid 566, while traveling through die 550. This causes tape520 to solidify upon exiting die 550. In this embodiment, pressurizedfluid 566 is supplied to chambers 564 from supplies 540 via ports 542.Furthermore, chambers 564 are downstream of entrance 552. FIG. 5Billustrates a cross-section of die 550 further illustrating ports 542,chambers 564, channel 556, and cross-sectional shape 557. FIG. 5Bcorresponds with view arrows 5B of FIG. 5A.

In a further embodiment, each piece of die 550 is removably mounted inplace (e.g., via screws, clamps, etc.). In this manner, pieces of die550 may be removed and replaced with pieces having different radii ofcurvature. Processing may then be resumed (e.g., for the same spool 510of tape 520) to apply the new curvature to a different section of tape520.

Tape 520 is pulled out of exit 558 of die 550 via rollers in region 10.In this embodiment, the rollers include roller 590 and roller 580.Roller 590 rotates in direction 592, and roller 580 rotates in direction582. Roller 590 and roller 580 may jointly be referred to as a “noodletensioning device.” A nip 584 between roller 590 and roller 580 providesgripping and pulling action to tape 520. The rollers apply a pullingforce (e.g., one hundred pounds of force) in order to pull tape 520(which has now been formed into preform 250) out of die 550. This forcealso applies tension to tape 520, ensuring that tape 520 remains taught.In further embodiments, roller 580, roller 590, and/or spool 510 mayinclude a clutch and/or brake to facilitate tension control.

Lengths of preform 250 may then be stored for later application to alaminate that will be cured into a composite part. Throughout theprocess, controller 596 may regulate unwinding, feeding, and pulling oftape 520 by preventing tension at tape 520 from exceeding a target valueor going outside of a target range.

Controller 596 may manage the various operations of the components ofpultrusion system 500 described above. For example, controller 596 mayadjust an amount of pulling force applied by rollers 580 and 590, anamount of pressurized fluid applied via passages 568 which couplecooling chambers 564 to channel 556, or an amount of heat applied byheaters 530 in order to ensure that a steady-state process is reachedwherein the unwinding, heating, feeding, cooling and pulling areperformed simultaneously upon the tape at different locations along thetape. Controller 596 may be implemented, for example, as customcircuitry, as a hardware processor executing programmed instructions, orsome combination thereof. A sensor 598 is also depicted in FIG. 5A, andmay be utilized by controller 596 to determine/monitor a speed ofpultrusion of tape 520. Controller 596 may therefore engage in activefeedback control by regulating the pulling force of roller 580 androller 590 based on input from sensor 598. Sensor 598 may comprise acamera, a laser, a rolling conveyor sensor, etc. Sensor 512 at spool 510detects the amount of torsion to be applied to keep tape 520 at adesired level of tension. Sensor 513 may also be utilized by controller596 to provide feedback control of the rollers 580 and 590 to maintaindesired feed rate. Roller 510 provides tension in tape 520 to ensureintimate contact between fibers during the forming process. Rollers 590and 580 are controlled to maintain feed rate of material through thesystem.

In a further embodiment, roller 580 and/or roller 590 include sensorsthat measure resistance of tape 520 to being pulled. This measure isindicative of a level of tension at tape 520. Hence, controller 596 mayutilize input from roller 580 and/or roller 590 to adjust an amount offorce applied by these rollers to tape 520. This may be performed inorder to ensure that tension at tape 520 is kept between a desiredminimum and maximum level of tension.

FIGS. 6-10 illustrate various arrangements of rollers for pultrusionsystem 500 that forms nip 584 in an exemplary embodiment. FIGS. 6-9illustrate these rollers from a cross-sectional view indicated by viewarrows 6 of FIG. 5A. FIG. 10 illustrates a roller from a side view ofregion 10 of FIG. 5. FIG. 6 illustrates a pair of rollers 602 and 604which pull a preform 250 having a triangular cross-section 620. In thisembodiment, roller 604 includes a groove 610 which corresponds with twoof the sides (682, 684) of nip 584 for handling preform 250. Meanwhile,roller 602 corresponds with a third side of the nip for handling preform250. Rollers 602 and 604 may be held against or in relation with eachother at a desired level of force (e.g., fifty pounds of force) toensure that they are in contact with preform 250, or may be mounted toensure a desired level of friction (and therefore pulling force) isapplied to preform 250 as rollers 602 and 604 rotate. FIG. 7 illustratesa similar embodiment to that of FIG. 6, wherein a roller 704 with agroove 710 works in tandem with another roller 702. However, in FIG. 7roller 702 includes a curved surface 712 to conform the edge of the nipwith a preform 250 having a curved cross-section (e.g., in circumstanceswhere die 550 enforces a curved shape on one or more sides of tape 520,necessitating a nip with a curved edge). FIG. 8 illustrates a furtherembodiment wherein three separate rollers 800, 810, and 820 each areheld in contact with a different side of preform 250. In furtherembodiments, any suitable number of rollers (e.g., three) may beutilized (e.g., to form a nip contacting any suitable number of sides ofpreform 250). In some embodiments, nip 584 is slightly smaller than thecross-section of preform 250, which facilitates gripping/friction whenpulling preform 250 forward.

FIGS. 9-10 illustrate a further embodiment wherein rollers 902 and 900exhibit different sizes (FIG. 10 corresponds with region 10 of FIG. 5A).In such embodiments, the rotation speed and/or torque applied by therollers may be adjusted to ensure that tape 520 travels between therollers without delay and without breaking. Roller rotation speeds atthe nip and reel torque resistance may be analyzed to control pullspeeds throughout the process without breaking preform 250. In thisembodiment, roller 900 is a large drum having a groove 910 with an innerradius 1000 corresponding to inner radius 562 of die 550, and an outerradius 1010 corresponding with outer radius 572 of die 550. By utilizingthis combination of rollers, preform 250 is not subjected to stresses orstrains that could otherwise result from pulling preform 250 “straightout” of (i.e., in a direction perpendicular to) the exit of die 550. Inthis manner, kinking of preform 250 is prevented as preform 250 exitsdie 550. That is, the combination of rollers helps to prevent furthercurvature (or undesired curvature) from being applied to preform 250after exiting die 550. The exit of die 550 may have a smallercross-sectional area than an inlet of die 550. This may correspond tothe decrease in cross-sectional area of tape 520 as tape 520 is pulledthrough die 550.

FIG. 11 illustrates a further embodiment which utilizes a roller 1100having a helical groove 1110 in an exemplary embodiment. Roller 1100interacts with roller 1102 to pull preform 250. Helical groove 1110includes ridges 1120. In this embodiment, helical groove 1110 continuesalong a circumference of roller 1100 as roller 1100 rotates along anAxis of Rotation (AOR) in order to wrap preform 250 multiple times alongroller 1100 for storage. Hence, groove 1110 is coiled about roller 1100like a helical spring. Roller 1100 translates along the AOR duringrotation as indicated by arrow 1130, causing preform 250 (formed fromtape 520) to wrap into helical groove 1110. In this manner, preform 250may be wrapped about the circumference of roller 1100 multiple times(e.g., like a coil). This increases the amount of preform 250 that maybe stored at roller 1100.

Illustrative details of the operation of pultrusion system 500 will bediscussed with regard to FIG. 12. Assume, for this embodiment, that anoperator has loaded a spool 510 of tape 520, and has fed an angled(e.g., cut) tip of tape 520 through die 550 and into rollers 580 and590. Thus, a leader section of preform 250 may exist which does not yethave a desired cross-section or curvature. This leader section may bepulled through pultrusion system 500 and then removed. Hence, the leadersection is used to prime the process of preform creation, and will notbe a part of the preform 250 as laid-up into a composite part.Pultrusion system 500 is capable of drawing additional tape 520 throughdie 550 by operation of rollers 580 and 590.

FIG. 12 is a flowchart illustrating a method 1200 for operating apultrusion system in an exemplary embodiment. The steps of method 1200are described with reference to pultrusion system 500 of FIG. 1, butthose skilled in the art will appreciate that method 1200 may beperformed in other systems. The steps of the flowcharts described hereinare not all inclusive and may include other steps not shown. The stepsdescribed herein may also be performed in an alternative order.

Controller 596 directs operation of driven rollers 580 and 590 toinitiate rotation, which applies friction to preform 250, causingpreform 250 (and therefore tape 520) to advance, being pulled fromupstream to downstream. This results in unwinding of tape 520 from spool510 (step 1202). During this process, controller 596 may actively useinput from sensors (e.g., sensor 598) to regulate an amount of forceapplied by roller 580 and roller 590, in order to ensure that tension ismaintained at a desired level via nip 584. Thus, nip 584 may bedimensioned to be smaller than the cross section of preform 250 in orderto provide sufficient clamping force. The material geometry of preform250 has already been set by the heating, forming and cooling process.Thus, when preform 250 is compressed at nip 584, the shape of preform250 will fully recover once preform 250 exits nip 584.

After unwinding from spool 510, tape 520 is pulled across heaters 530,which apply heat (Δ of FIG. 5A) that raises tape 520 above a stickingpoint temperature for thermoplastic binder 340 (step 1204). The heatingprocess occurs within one section of tape 520 at L2 as tape 520continues to be unwound at L1.

Roller 580 and 590 continue operation, causing tape 520 to be fedthrough die 550 while tape 520 is heated to (i.e., at or above) thesticking point temperature (step 1206). Die 550 forms tape 520 intopreform 250. Die 550 may exhibit a substantially differentcross-sectional area than tape 520 does before entering die 550. Forexample, die 550 may exhibit one tenth of the width of tape 520 asstored at spool 510. This means that a great deal of compressivepressure is applied to tape 520 (e.g., one hundred pounds per squareinch or more) as tape 520 enters die 550 and forms preform 250. Die 550exhibits a curvature (e.g., radius 562 and radius 572) through whichpreform 250 travels. This curvature is enforced onto preform 250, andcauses fibers 512 and 514, and/or plies to slip with respect to eachother while tape 520 remains malleable. In this manner, the path lengthsof fibers within preform 250 are varied as preform 250 passes throughdie 550 (step 1208). As preform 250 continues traveling through die 550,preform 250 is cooled below the sticking point temperature (step 1210)by application of pressurized fluid 566 to passages 568 (or other meansdiscussed above). This solidifies thermoplastic binder 340 withinpreform 250, which hardens preform 250.

Rollers 580 and 590 continue to operate to pull preform 250 out of die550 after preform 250 has been cooled below the sticking pointtemperature (step 1212). Preform 250 pulled from die 550 may then bestored on a drum for later application to a laminate that will be curedinto a composite part.

Method 1200 provides a substantial benefit over prior techniques forforming preforms, because method 1200 allows for preforms 250 which arecurved along their length to be formed via pultrusion processes. Thistechnique prevents wrinkle formation when a preform 250 is applied to alaminate awaiting curing. Furthermore, this technique allows for rapidand economical automated fabrication of preforms.

Examples

In the following examples, additional processes, systems, and methodsare described in the context of a pultrusion system that utilizes acurved die.

FIG. 13 is a block diagram of a pultrusion system 1300 in an exemplaryembodiment. Pultrusion system 1300 heats, shapes, and cools tape 1320 inorder to conform with a desired curvature. In this embodiment,pultrusion system 1300 includes spool 1310, about which tape 1320 iswound. Tape 1320 includes a thermoplastic or thermoset binder 1324, aswell as carbon fibers 1322 which reinforce the strength of tape 1320. Inthis example, heaters 1330 apply radiant heat that increases thetemperature of tape 1320 until tape 1320 is pliable. Tape 1320 proceedsinto die 1340, which includes pieces 1342. Each piece 1342 defineseither an inner or an outer radius of curvature. In this embodiment,each piece 1342 further comprises a chamber 1344 and multiple passages1346. Pressurized air from supply 1352 enters a chamber 1344 via port1350 in order to cool tape 1320, causing tape 1320 to solidify whileexhibiting the desired curvature. Rollers 1360 pull tape 1320, which hasbeen cooled until it has hardened into preform 1370, out of die 1340 foruse in laying up a composite part.

Referring more particularly to the drawings, embodiments of thedisclosure may be described in the context of an aircraft manufacturingand service method 1400 as shown in FIG. 14 and an aircraft 1402 asshown in FIG. 15. During pre-production, exemplary method 1400 mayinclude specification and design 1404 of the aircraft 1402 and materialprocurement 1406. During production, component and subassemblymanufacturing 1408 and system integration 1410 of the aircraft 1402takes place. Thereafter, the aircraft 1402 may go through certificationand delivery 1412 in order to be placed in service 1414. While inservice by a customer, the aircraft 1402 is scheduled for routinemaintenance and service 1416 (which may also include modification,reconfiguration, refurbishment, and so on). Apparatus and methodsembodied herein may be employed during any one or more suitable stagesof the production and service method 1400 (e.g., specification anddesign 1404, material procurement 1406, component and subassemblymanufacturing 1408, system integration 1410, certification and delivery1412, service 1414, maintenance and service 1416) and/or any suitablecomponent of aircraft 1402 (e.g., airframe 1418, systems 1420, interior1422, propulsion 1424, electrical 1426, hydraulic 1428, environmental1430).

Each of the processes of method 1400 may be performed or carried out bya system integrator, a third party, and/or an operator (e.g., acustomer). For the purposes of this description, a system integrator mayinclude without limitation any number of aircraft manufacturers andmajor-system subcontractors; a third party may include withoutlimitation any number of vendors, subcontractors, and suppliers; and anoperator may be an airline, leasing company, military entity, serviceorganization, and so on.

As shown in FIG. 15, the aircraft 1402 produced by exemplary method 1400may include an airframe 1418 with a plurality of systems 1420 and aninterior 1422. Examples of high-level systems 1420 include one or moreof a propulsion system 1424, an electrical system 1426, a hydraulicsystem 1428, and an environmental system 1430. Any number of othersystems may be included. Although an aerospace example is shown, theprinciples of the invention may be applied to other industries, such asthe automotive industry.

As already mentioned above, apparatus and methods embodied herein may beemployed during any one or more of the stages of the production andservice method 1400. For example, components or subassembliescorresponding to production stage 1408 may be fabricated or manufacturedin a manner similar to components or subassemblies produced while theaircraft 1402 is in service. Also, one or more apparatus embodiments,method embodiments, or a combination thereof may be utilized during theproduction stages 1408 and 1410, for example, by substantiallyexpediting assembly of or reducing the cost of an aircraft 1402.Similarly, one or more of apparatus embodiments, method embodiments, ora combination thereof may be utilized while the aircraft 1402 is inservice, for example and without limitation, to maintenance and service1416. For example, the techniques and systems described herein may beused for steps 1406, 1408, 1410, 1414, and/or 1416, and/or may be usedfor airframe 1418 and/or interior 1422. These techniques and systems mayeven be utilized for systems 1420, including for example propulsion1424, electrical 1426, hydraulic 1428, and/or environmental 1430.

In one embodiment, preform 250 comprises a portion of a stringer atairframe 1418, and is manufactured during component and subassemblymanufacturing 1408. The stringer may then be assembled into an aircraftin system integration 1410, and then be utilized in service 1414 untilwear renders the stringer unusable. Then, in maintenance and service1416, the stringer may be discarded and replaced with a newlymanufactured stringer, or may be repaired. New preforms 250 may beutilized throughout component and subassembly manufacturing 1408 inorder to facilitate fabrication of the new stringer.

Any of the various control elements (e.g., electrical or electroniccomponents) shown in the figures or described herein may be implementedas hardware, a processor implementing software, a processor implementingfirmware, or some combination of these. For example, an element may beimplemented as dedicated hardware. Dedicated hardware elements may bereferred to as “processors”, “controllers”, or some similar terminology.When provided by a processor, the functions may be provided by a singlededicated processor, by a single shared processor, or by a plurality ofindividual processors, some of which may be shared. Moreover, explicituse of the term “processor” or “controller” should not be construed torefer exclusively to hardware capable of executing software, and mayimplicitly include, without limitation, digital signal processor (DSP)hardware, a network processor, application specific integrated circuit(ASIC) or other circuitry, field programmable gate array (FPGA), readonly memory (ROM) for storing software, random access memory (RAM),non-volatile storage, logic, or some other physical hardware componentor module.

Also, a control element may be implemented as instructions executable bya processor or a computer to perform the functions of the element. Someexamples of instructions are software, program code, and firmware. Theinstructions are operational when executed by the processor to directthe processor to perform the functions of the element. The instructionsmay be stored on storage devices that are readable by the processor.Some examples of the storage devices are digital or solid-statememories, magnetic storage media such as a magnetic disks and magnetictapes, hard drives, or optically readable digital data storage media.

Although specific embodiments are described herein, the scope of thedisclosure is not limited to those specific embodiments. The scope ofthe disclosure is defined by the following claims and any equivalentsthereof.

What is claimed is:
 1. A system comprising: a heater that heats fiberreinforced material to a sticking point temperature of a constituentmaterial of the fiber reinforced material; a pultrusion die, downstreamof the heater, that exhibits a channel that forms the fiber reinforcedmaterial into a preform for a gap filler; a cooling chamber that placesthe fiber reinforced material into direct contact with a fluid; androllers that form a nip for receiving the preform.
 2. The system ofclaim 1 wherein: the cooling chamber is internal to the pultrusion die.3. A system comprising: at least one spool for holding a roll of fiberreinforced material comprising a constituent material; a heaterdownstream of the spool that heats the fiber reinforced material to asticking point temperature of the constituent material; a pultrusiondie, downstream of the heater, that exhibits a channel having alengthwise curvature that is enforced upon a length of the fiberreinforced material, and forms the fiber reinforced material into apreform for a gap filler; a cooling chamber that places the fiberreinforced material into direct contact with a fluid; and rollers thatare located downstream of the pultrusion die and form a nip in across-sectional shape of the pultrusion die.
 4. The system of claim 3wherein: the constituent material comprises a thermoplastic binder; andthe heater comprises a radiant heater that heats the fiber reinforcedmaterial to between 150 and 200 degrees Celsius.
 5. The system of claim3 wherein: an entrance to the pultrusion die is curved.
 6. The system ofclaim 5 wherein: the entrance to the pultrusion die is circular.
 7. Thesystem of claim 3 wherein: the pultrusion die comprises removable pieceswhich may be interchanged to adjust a radius of the curvature.
 8. Thesystem of claim 3 wherein: an exit of the pultrusion die has a smallernet cross-sectional area than an inlet of the pultrusion die.
 9. Thesystem of claim 3 wherein: one of the rollers comprises a helical groovethat extends along a circumference of the roller, and the helical groovematches a cross section of the preform after the preform exits thepultrusion die.
 10. The system of claim 9 wherein: the roller translatesaxially along its axis of rotation during rotation, causing the preformto wrap into the helical groove.
 11. The system of claim 3 wherein: therollers comprise a roller having an outer radius equal to the curvatureof the pultrusion die, and the roller applies tension to the preformexiting the pultrusion die by rotating.
 12. The system of claim 3wherein: at least one of the rollers comprises a groove correspondingwith a shape of at least one side of the preform after exiting thepultrusion die.
 13. The system of claim 3 wherein: the rollers comprise,for each side of the preform as the preform exits the pultrusion die: aroller directly contacting the side of the pultrusion die and matching ashape of the side of the pultrusion die.
 14. The system of claim 3wherein: the cooling chamber is within the pultrusion die.
 15. Thesystem of claim 3 wherein: the pultrusion die is made from a materialselected from the group consisting of metal and plastic.
 16. A systemcomprising: at least one spool for holding a roll of fiber reinforcedmaterial comprising a constituent material; a heater downstream of thespool that heats the fiber reinforced material to a sticking pointtemperature of the constituent material; a pultrusion die, downstream ofthe heater, that exhibits a channel having a lengthwise curvature thatis enforced upon a length of the fiber reinforced material, and formsthe fiber reinforced material into a preform; a cooling chamber throughwhich pressurized fluid is configured to travel, that cools the preform;rollers that are located downstream of the pultrusion die and form a nipin a cross-sectional shape of the pultrusion die; and a controllerconfigured to manage adjustment at least one of: an amount of pullingforce applied by the rollers on the preform, an amount of thepressurized fluid applied to cool the preform, or an amount of heatapplied by the heater, in order to ensure that a steady-state process isreached wherein unwinding, heating, feeding, cooling and pulling areperformed simultaneously upon the preform at different locations alongthe preform.
 17. The system of claim 16 wherein: the constituentmaterial comprises a thermoplastic binder; and the heater comprises aradiant heater that heats the fiber reinforced material to between 150and 200 degrees Celsius.
 18. The system of claim 16 wherein: thepultrusion die comprises removable pieces which may be interchanged toadjust a radius of the curvature.
 19. The system of claim 16 wherein:wherein one of the rollers comprises a helical groove that extends alonga circumference of the roller, and the helical groove matches a crosssection of the preform after the preform exits the pultrusion die. 20.The system of claim 16, wherein: an exit of the pultrusion die has asmaller net cross-sectional area than an inlet of the pultrusion die.